Production Management A – Winter Semester 2009/10
Technology Management 2 P. 0
Exercise 2
Production Management A
Exercise
Technology Management 2
Organisation:
Dipl.-Ing. Sebastian Nollau
Steinbachstr. 17Raum 235
Tel.: [email protected]
Laboratory for Machine Tools and Production Engineering
Chair of Production EngineeringProf. Dr.-Ing. Dipl.-Wirt. Ing. G. Schuh
Chair of Production ManagementProf. Dr.-Ing. A. Kampker
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 1
Exercise 2
Index:
Index Page 1
Aim of this exercise Page 2
Exercise Page 3
Introduction into the Technology Calendar
Case study: A380 engine components
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 2
Exercise 2
Aims of this exercise:
It is the goal of the second exercise of the technology management block of
lectures to deepen the insights from the lecture and to give an industrial
example for the roadmapping techniques.
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 3
Exercise 2
Page 3© WZL/Fraunhofer IPT
Structure
Introduction of the technology calendar1
Case study: A380 engine components2
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 4
Exercise 2
Page 4© WZL/Fraunhofer IPT
Why Technology Roadmapping?
Roadmaps…
� … help you to define your current situation and your target
� … support in finding the right way to your target
� … allow you to define interstations
� … offer flexibility in case of
– roadblocks
– changing targets
Technology Roadmapping…
� requires as-is-analysis and target definition
� shall support deriving the right way with intermediate results
� shall deliver operative support and flexibility in execution
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 5
Exercise 2
Page 5© WZL/Fraunhofer IPT
Proceeding for creation of a technology calendar
technology identification
product analysis and generation of ideas
technology assignment
technology assessment
realisation planning
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 6
Exercise 2
Page 6© WZL/Fraunhofer IPT
Product analysis and generation of ideas
� Identification of solution concepts
� Identification of approaches fromother branches
� List of approaches, e.g. regarding: - Change of design- Change of process chains- Change of materials
Documentation of results in PDS Generation of Ideas
Abstraction
Product Data
Sheet
As-Is data
Abstraction
Approaches
Legend: PDS = Product Data Sheets
PDS samples
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 7
Exercise 2
Page 7© WZL/Fraunhofer IPT
Product analysis
� Analysis of technological data(geometries, tolerances, materials etc.)
� Functional analysis
� Load analysis
� Interface analysis
� Organisational framework
Generation of ideas
� Abstraction from the propertiesof the part
� Generation of solutions and of interdisciplinary approaches
� List of approaches for exampleto:- Change physical appearance- Change process- Change materials employed
GGestalt f reiheit
GGestalt f reiheit
GGGestalt f reiheit
BelastungBelastungBelastung
Schnit t stelleSchnit t stelleSchnit t stelle
µµµµ
Verschleiß
µµµµ
Verschleiß
µµµµµµµµ
Verschleiß
Oberf lächeOberf lächeOberf läche
ToleranzToleranzToleranz
Example: Mechanical load analysis for a gear wheel
Example product analysis
G
–
– Gegeben durch Schnittstellen
– Flanken
–
−
– Hohlrad
– Sonne
– Ritzel
– Anlagefläche:
– Parallelit ät der Anlagefl ächen
– Keine phosphortierten Scheiben
– Roughness
Rauheit
Durchmessertoleranz:
– Zahnflanken: Q 7
– Entgraten
– Montagehilfe
– Entgraten
– Maximum
– Minimum
– Zahnfußbiegespannung
–
− Durchmessertoleranz: − Roundness− Ma ß
G
GG
–
–
–
–
−
–
–
–
– Contact surface
– ät der Anlagefl ächen
– No phosphorized wheels
–
Roughness
Radius tolerance
– Q 7
–
–
–
–
–
–
–
−
−
−
GG
Parallelity of the contact surface
Interfaces
Flanks
Tooth geometry
Tooth type
Tooth base tension
Life cycle
Default position
Radius tolerance
Dimensional accuracy
Assembly aids
Deburring
Ring gear
Sun
Pinion
Tooth flanks
Deburring
Tolerance
Surface
Abrasion
Interface
Load
Freedom of design
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 8
Exercise 2
Page 8© WZL/Fraunhofer IPT
Analysis of information need:
Definition of search areas
� Monitoring Radar
– Structuring of relevant
search areas
– Enabling of the
aggregation of search
tasks
– „Peering over the rim of
the proverbial tea cup“
Monitoring Radar(example)
long-term
medium-termshort-term
Key competence areas
Areas of basic technologies
Areas of interdisciplinary technologies
Grinding
Precise lasermachining
Foamingof metals
Laser-welding
Thixoforming
Steel
Glueing
Forming
Welding
Timing perspective
ControlledMetal Build
up
Hydrojet-
Cutting
Aluminium-machining
Eroding
Tools
Ceramic-machining
Plasticsprocessing
long-term
medium-termshort-term
HSC-machining
Trochoidalmachining
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 9
Exercise 2
Page 9© WZL/Fraunhofer IPT
Sources of information
� Internal information network
– Colleagues, technology experts, working groups
– Internal data, protocols, earlier projects
� External sources
– Research institutes, universities
– Suppliers, cooperation partners
– Customers
– Agencies
– Patent analysis, databases, internet
� Structured investigation of technologies
– Questioning of experts
– Visit of fairs, seminats and conferences
– Analysis of competition
– Consideration of analogies
– Reference applications
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 10
Exercise 2
Page 10© WZL/Fraunhofer IPT
Determine
Information need
Gather
information
Assess
Information
Communicate
key learnings
System-based focusing
Patent analysis Workshops Expert
surveys
Portfolio Analysis Technicalevolution
Other
roadmaps
Technology
Data Sheets
Technology identification (Examples of methods)
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 11
Exercise 2
Page 11© WZL/Fraunhofer IPT
Informationen beschaffen mittels Scanning,
Monitoring und Scouting
Monitoring
Scanning
Scouting
Task AimPerspectiveObject
Technology-relatedbusiness environment
certaintechnology areas
certaintechnology topics and knowledge carriers
Nondirectional and unfocussed
source: Ashton/Klavans 1997
Overview of global Technology trends
Directional and weaklyfocussed
Following the eventsin relevant fields oftechnology
Assigned acquisitionof detailed technologyinformation
Directional and stronglyfocussed
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 12
Exercise 2
Page 12© WZL/Fraunhofer IPT
Example consumer goods:
Analysis of potential for lightweight construction
Experts
Institutes/
Organisations
Agencies/ associations
RWTH-Network
Industrial companies/
Partner companies
Project experiences
Norms (DIN 8580)
Internet
Datbases
Fhg-Network
Examples from
different areas
Events/ fairsBrainstorming / collection of information
on lightweight construction & technology
34 approaches
20 ideas after priorization
Specification of priorized approaches and
identification of 8 additional ideas
28 Ideas
3 technologies for detailed analysis
1 technology as R&D project
Literature
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 13
Exercise 2
Page 13© WZL/Fraunhofer IPT
Technology assignment
Object of examination Analogy to
Nail production
Current production chain Alternative technology chain
Turbine production: Rivetting Turbine production: Pressure joining
Pump production: Gluing
Halogen lamp production
Pump production
Peak drawingmax 1000 pcs./min
Rotary swagingmax 80 pcs./min
Legend: b: blading d: drilling e: threading f: pressure joining h: hardeningj: alignment k: gluing l: hard soldering n: rivetting p: packetings: blanking v: copperplating
� Different concepts for
realisation of current and
future projects are
available
� Systematic forecasting
and investigation
identifies technology
alternatives
� Technologies/ technology
chains are assigned to
product concepts
����Aim: Alignment of
product specifications
and technologies!
Generation of possible technology chains
Abstract product specifications
s v p b l s b k h
d j e n f
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 14
Exercise 2
Page 14© WZL/Fraunhofer IPT
Technology assessment: Portfolio technique
Technologieportfolio
Relative Technologieposition
Te
chn
olo
gie
attra
ktivitä
t
0,0
1,0
2,0
3,0
4,0
5,0
0,0 1,0 2,0 3,0 4,0 5,0
Konzept B
Konzept C
Konzept A
Marktportfolio
Relativer Wettbewerbsvorteil
Ma
rkta
ttra
ktivitä
t
0,0
1,0
2,0
3,0
4,0
5,0
0,0 1,0 2,0 3,0 4,0 5,0
Konzept B
Konzept C
Konzept A
Attraktivität
Ris
iko
Risikoportfolio
0,0
1,0
2,0
3,0
4,0
5,0
0,0 1,0 2,0 3,0 4,0 5,0
KonzeptC
Konzept B
KonzeptA
Ertragsportfolio
Erfolgswahrscheinlichkeit
Ert
rag
spo
ten
zia
l
0,0
1,0
2,0
3,0
4,0
5,0
0,0 1,0 2,0 3,0 4,0 5,0
KonzeptA
Konzept B
Konzept C
� Transparent and comprehensible assessment,
prioritisation and selection of technologies and projects
� Focused resource allocation
� Regarding technological and economical criteria
� Company-specific selection of assessment criteria
� Holistic, but still focused technology and project
assessment
� Use of portfolios as means of information transparency
and communication
� Constructive discourse instead of simplistic key figures
Technology portfolio
Market portfolio
Risk portfolio
Earnings portfolio
Comparative
technology position
Success probability
Technology attractiveness
Comparative competitive
advantage
Mark
et
att
ractiven
ess
Ris
k
Earn
ing
sp
ote
ntia
l
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 15
Exercise 2
Page 15© WZL/Fraunhofer IPT
Technology assessment: Proceeding
� Benefit criteria, e.g.:
– cycle times
– max. output/time
– Quality (z.B. scrap rate)
� Effort criteria, e.g.:
– Acquisition costs
– Investment
– Consumables
� Elimination of technologies which
– do not fullfil k.o. criteria
– are significantly dominated by alternative technologies in all
criteria
– if patented, are not available for acquisition (e.g. license)
� Assessment of remaining technologies
� Summary of criteria to dimensions benefits and efforts, e.g. with
value benefit analysis
Definition of assessment
criteria
� k.o. criteria
� scalable criteria
Technology assessment
Ben
efi
t
Efforthigh
hig
h
medium
me
diu
mlo
w
low
3
14
2
67
8
9
10
1213
1415
16
1819
20
21
22
2425
26
27
17
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 16
Exercise 2
Page 16© WZL/Fraunhofer IPT
Communicating the findings:
Idea datasheets (examples)
Pro‘s and con‘s
Short description
Available technology experts
Related parts
Aluminum foams
ALuminum-Magnesium coatings
Short description
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 17
Exercise 2
Page 17© WZL/Fraunhofer IPT
Realisation planning: Example: Technology calendar fuel cell
Proceeding
� Deduction of technology acquisition demand
� Identification of technology sources:– in-house development
– Mergers & acquisitions
– Joint Ventures
– Development cooperations
– External development
– Technology licensing
� Determination of timing, milestones and fall-back
solutions
Results
� Deducted development projects
� Technology acquisition activities
� Timing alignment between product and technology
portfolio
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 18
Exercise 2
Page 18© WZL/Fraunhofer IPT
Structure
Introduction of the technology calendar1
Case study: A380 engine components2
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 19
Exercise 2
Page 19© WZL/Fraunhofer IPT
Case study: Airbus A380 Technology calendar for engine components
GP7000 (General Electric)Airbus A380
Source: General Electric
Source: Rolls-Royce
Trent 900 (Rolls-Royce)
� Both competitors equally share the market
� Airlines decide which engines they want to use
� Success factors:
– Specific Fuel Consumption (SFC)
– Overall weight
– „Cost per flight hour“
– Noise
Source: EADS
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 20
Exercise 2
Page 20© WZL/Fraunhofer IPT
Principle of function: Turbofan engine
� Main use: Civil aviation
� High bypass air flow
� Process comparable to 4-cycle
engine, but all processes
happen in parallel:
– Compress (1)
– Combust (2)
– Expand (3)
– Eject (4)
� Compressor consists of up to 9
stages
� Turbine consists of up to
7 stages
� each stage
= Disc + blades, or
= Blisk (Integrally bladed disc) 1
Compress
2
Combust
3
Expand
4
Eject
Bypass air flow
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 21
Exercise 2
Page 21© WZL/Fraunhofer IPT
Blade-disc-systems vs. blisk (blade integrated disk)
Blade on disc withfoot profile
Blisk (welded blades)
� Blade foot profile is pressed into disc profile,
then form-locked against axial movement
� No alternative to blade-disc-system for hollow
blades with cooling holes
� Welded blades or alternatively milling from solid
(very expensive, esp. used for highly stressed
parts (e.g. monocrystalline materials))
� In the case study, stage 2 of the compressor is
going to be a blisk from September 2008 and
will fully substitute the old technology 9 months
later
Source: Blacks Equipment Ltd & MTU
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 22
Exercise 2
Page 22© WZL/Fraunhofer IPT
Conventional technology: Blade-disc-systems
Source: Rolls Royce
� One compressor blade of 10 cm length delivers as much
power as a Formula 1 racing car
� Gas temperatures in turbine partially exceed melting
temperature of blade alloys
�Cooling holes and blade coatings lower surface
temperature
� Cooling holes are manufactured by Electrical Discharge
Machining (EDM) or laser drilling
� Use of blisks only feasible for uncooled blades!
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 23
Exercise 2
Page 23© WZL/Fraunhofer IPT
High importance of after-sales for engine manufacturers
� Lifecycle of aircrafts: approx. 20 years
� High attrition of engine components
� Engines to be maintained yearly, first review of engineblades 6 months after start of operation
� After-sales business amounts to more than 60% of engine manufacturers‘ turnover
� Blisk reparation process:
� Large defects: Milling of weared-out blades and weldingof new blades
and/ or:
� Smaller defects: Deposit welding at attrition spots and regrinding
Quelle: Rolls-Royce
Engine manufacturers often provide engines for free to the aircraft manufacturers, so thatthe turnover only comes from the after-sales business!
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 24
Exercise 2
Page 24© WZL/Fraunhofer IPT
Structure of the technology calendar (template)
2009 2012 t
Pro
ducts
Technolo
gie
s
2010 2011
Rep
air
New
part
s
� Date of planning:
November 2009
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 25
Exercise 2
Page 25© WZL/Fraunhofer IPT
Technology identification for blisk production:Definition of search areas
� Minimal hardness and microstructure within component
(component is safety-critical!)
� high accuracy regarding rotational movement
� Joining technologies
� Stripping (starting from solid)
� Joining and stripping technologies in fields of
– Automotive (turbocharger, cycle engines etc.)
– Pump systems (rotors)
– Tool & Die Making
– Process engineering applications
(pressure tanks)
Definition of requirements
Technical alternatives
Deducted search areas
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 26
Exercise 2
Page 26© WZL/Fraunhofer IPT
Technology identification for blisk production:Results of technology investigation
Joining technologies
� Linear friction welding
� Stir friction welding
� Laser-assisted stir friction welding
� Laser welding
� High frequency press welding
� Inductive welding
� Hard soldering
� Laser soldering
� Laser powder build up welding
Stripping technologies
� (Conventional) Grinding
� (Conventional) Milling
� Trochoid Milling
� High Speed Cutting (HSC)
� Eletrical Discharge Machining (EDM)
� Electro-Chemical Machining (ECM)
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 27
Exercise 2
Page 27© WZL/Fraunhofer IPT
Technology assignment
2009 2012 t
Pro
ducts
Technolo
gie
s
Blade Stage 2
Disc Stage 2Compressor blisk 2
2010 2011
Rep
air
New
part
s
� Adequate technologies for
new part manufacturing:
– Electro-Chemical Machining
(ECM)
– Linear friction welding
� Adequate technologies for
blisk reparation:
– (Conventional) milling
– Linear friction welding
– Laser build-up welding
– (Conventional) grinding
production at max. level:
6/2011
planned start of production: 9/2010
first parts in reparation: 3/2011
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 28
Exercise 2
Page 28© WZL/Fraunhofer IPT
Technology assessment: Blisk manufacturing
� Redox reaction of blisk (anode) and tool (cathode) in electrolyte (NaCl)
� Expensive (high power demand), suitable only for smallproduction volumes
� metalhydroxid slurry is harmful for the environment
� R&D time schedule till series use: 6 months
� Blisk joining from disc with foot sockets and blades
� Linear frictive movement causes heat and melting of material at contact area
� Suitable for high and low volumes
� Also suitable for repair of blisks (Exchange of blades)
� R&D time schedule till series use : 12 months
Linear friction welding
Electro-Chemical
Machining (ECM)
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 29
Exercise 2
Page 29© WZL/Fraunhofer IPT
Technology assessment: Blisk reparation
� see: blisk manufacturing
� Repair technology for blisks to compensate lost material (e.g. edge breakouts, edge wear)
� Following grinding creates final shape
� Technology is patented by an external company and isdistributed via licensing
� Process integration of technology into existing processchain necessary
� Time for process integration: 2 months
� established technologies
� R&D unnecessary
Linear friction welding
Laser build-up welding
Grinding & Milling
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 30
Exercise 2
Page 30© WZL/Fraunhofer IPT
Realisation planning: technology calendar
2006
Pro
ducts
Technolo
gie
s
2007
Deduction of activities in
the technology calendar
�Adding relevant
Product informationen
(Start of production etc.)
�Definition of necessary
time for R&D and
integration projects
Rep
air
New
part
s
Laser build-up welding
Linear friction welding
Linear friction welding
ECM
Grinding & Milling
t
Blade Stage 2
Disc Stage 2Compressor blisk 2
production at max. level:
6/2011
planned start of production: 9/2010
first parts in reparation: 3/2011
2009 20122010 2011
Comments:
Production Management A – Winter Semester 2009/10
Technology Management 2 P. 31
Exercise 2
Page 31© WZL/Fraunhofer IPT
Conclusion: Use of methods in technology management…
� creates transparency for management
� helps to trace back decisions
� supports to cope with complexity
� optimises the coordination of diversified activities
� encourages communication within company and supply
chain
� supports operationalisation of strategic objectives
� systemises the creation and protection of technology-
based competitive advantages
Comments: